Vehicle control apparatus

ABSTRACT

A vehicle control apparatus is disposed inside a housing for accommodating a transmission. The vehicle control apparatus includes a metal base, a resin case, a printed circuit board on which an electronic component mounts, and an oil-tight seal member. The metal base is made of metal. The resin case is attached to the metal base to form an interior space. The printed circuit board is disposed in the interior space. The oil-tight seal member is disposed between the metal base and the resin case to surround the printed circuit board. The electronic component is included in a control circuit for the transmission. The metal base and the oil-tight seal member are at a hydrogen bonding state, and the rein case and the oil-tight seal member are at a covalent bonding state.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Patent Application No. 2019-071257filed on Apr. 3, 2019, the disclosure of which is incorporated herein byreference.

TECHNICAL FIELD

The present disclosure relates to a vehicle control apparatus.

BACKGROUND

Devices for controlling a vehicle have been integrated with anelectromechanical system including a sensor, an actuator or anintegrated system having both of the sensor and actuator. Therefore, thedemand for miniaturization, heat resistance, sealability, resistanceagainst vibration, or the like of a control device has been increasing.For example, a control device may be disposed in an oil-immersionenvironment for satisfying the demand.

SUMMARY

The present disclosure describes a vehicle control apparatus forcontrolling a transmission for a vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentdisclosure will become more apparent from the following detaileddescription made with reference to the accompanying drawings. In thedrawings:

FIG. 1 is a cross-sectional view illustrating the configuration of a TCUaccording to a first embodiment;

FIG. 2 is an enlarged sectional view showing the configuration of anoil-tight structure;

FIG. 3 is an exploded perspective view of the TCU;

FIG. 4 is a plan view of a metal base;

FIG. 5 is a bottom view of a resin cover;

FIG. 6 is a flowchart showing an assembly process of the TCU;

FIG. 7 is a schematic view showing the interior of a transmission casein a see-through manner;

FIG. 8 is a cross-sectional view illustrating the configuration of a TCUaccording to a second embodiment;

FIG. 9 is a cross-sectional view illustrating the configuration of a TCUaccording to a third embodiment;

FIG. 10 is a cross-sectional view illustrating the configuration of aTCU according to a fourth embodiment;

FIG. 11 is a cross-sectional view illustrating the configuration of aTCU according to a fifth embodiment;

FIG. 12 is a cross-sectional view illustrating the configuration of aTCU according to a sixth embodiment; and

FIG. 13 is a cross-sectional view illustrating the configuration of aTCU according to a seventh embodiment.

DETAILED DESCRIPTION

A vehicle control device for controlling a vehicle may be disposed in anoil-immersion environment for satisfying a demand such asminiaturization, heat resistance, sealability, resistance againstvibration, or the like.

However, circuit components in a control device may deteriorate as oilenters the control device. For example, disconnection due to oilcorrosion or short circuit caused by foreign substances may happen. Withregard to a waterproof measure taken for the control device, a casing ofthe control device may be sealed by a silicon sealing material. However,in a situation where such a sealing structure is placed in oil, thesilicon sealing material may swell with oil. Therefore, the sealabilitymay not be maintained.

In one or more embodiments of the present disclosure, a vehicle controlapparatus has stable sealability even though the vehicle controlapparatus is covered by oil.

According to an aspect of the present disclosure, a vehicle controlapparatus is disposed inside a housing for accommodating a transmissionat an atmosphere of lubricant oil. The vehicle control apparatus may becovered by the lubricant oil. The vehicle control apparatus includes ametal base, a resin case, a printed circuit board and an oil-tight sealmember. The resin case is attached to the metal base to form an interiorspace. The printed circuit board has an electronic component mounted onthe printed circuit board. The electronic component is included in acontrol circuit for the transmission. The printed circuit board isdisposed in the interior space. The oil-tight seal member is disposedbetween the metal base and the resin case to surround the printedcircuit board. The metal base and the oil-tight seal member are at ahydrogen bonding state, and the resin case and the oil-tight seal memberare at a covalent bonding state.

The adhesion strength is enhanced as the metal base and the oil-tightseal member are at the hydrogen bonding state, and the resin case andthe oil-tight seal member are at the covalent bonding state.

In one or more embodiments of the present disclosure, the metal base ismade of aluminum and applied with anodizing treatment. Therefore, theinterface between the metal base and oil-tight seal member may be set atan optimal state for the hydrogen bonding.

In one or more embodiments of the present disclosure, the resin case isapplied with plasma treatment. Therefore, the interface between theresin case and the oil-tight seal member may be set at an optimal statefor the covalent bonding.

In one or more embodiments of the present disclosure, the oil-tight sealmember includes fluororubber. Therefore, the oil-tight seal member has arelatively high resistance to the oil for lubrication, and hasflexibility.

In one or more embodiments of the present disclosure, a recess foraccommodating the oil-tight seal member is disposed at one of the metalbase and the resin case, and a protrusion is disposed at the other oneof the metal base and the resin case for pressing a central portion ofthe oil-tight seal member accommodated in the recess. In a case wherethe resin case is attached to the metal base, the spacing formed betweenthe recess and the tip of the protrusion extending in an extensiondirection has a larger width than the spacing formed between the recessand the protrusion in a direction perpendicular to the extensiondirection. Therefore, it is possible to reduce vibration in a verticaldirection (or the extension direction) transmitted to the printedcircuit board when the vehicle is travelling. Hence, the resistanceagainst vibration may be enhanced.

In one or more embodiments, the resin case is integrated with aconnector penetrating inside and outside the housing. The connector hasa ventilation hole for communicating with the interior space between theresin case and the metal case and outside of the housing. A breathablefilter is disposed at a location where the ventilation hole faces theoutside of the housing.

Since the space formed between the metal case and the resin casecommunicates with outside through the ventilation hole provided at theconnector, the inner pressure does not change when the temperatureinside the housing changes. Therefore, it is possible to reduce stressapplied to the structure. Additionally, since the breathable filter at alocation where the ventilation hole faces the outside, it is possible toinhibit a situation in which foreign substances are mixed into thehousing. Moreover, the ventilation hole is provided at the connectorpenetrating inside and outside the housing, it is possible tominiaturize the vehicle control apparatus.

First Embodiment

As illustrated in FIG. 7, a valve body 2 having a hydraulic control oilpassage formed inside of the valve body 2 mounts on an inner bottom partof a transmission case 1 corresponding to a housing. The transmissioncase 1 may also be referred to as a T/M case 1. A transmission controlunit 3, which corresponds to a vehicle control apparatus according tothe present embodiment, is disposed on the valve body 2. Thetransmission control unit 3 may also be referred to as TCU 3. A metalbase 4 of the TCU 3 is substantially in a rectangular shape, and isfixed on the valve body 2 with a screw 5.

Automatic transmission fluid 50, which corresponds to oil forlubrication, is injected into the T/M case 1. The automatic transmissionfluid 50 may also be referred to as ATF 50. In other words, the TCU 3 isdisposed in the atmosphere of the ATF 50, and is covered by the ATF 50.The metal base 4 is made of, for example, aluminum applied withanodizing treatment (or alumite treatment). Although not shown,mechanism as a main body of the transmission is disposed inside the T/Mcase 1.

As illustrated in FIG. 1, a resin case 7 of the TCU 3 is attached to themetal base 4 through an oil-tight structure, and thus an interior spaceis formed. The resin case 7 may also be referred to as a resin cover. Aprinted circuit board 9 on which an electronic component 8 mounts isaccommodated in an interior space formed by attaching the resin case 7to the metal base 4 through the oil-tight structure. The details of theoil-tight structure are described hereinafter. The electronic component8 includes a control circuit for transmission. However, the details ofthe electronic component 8 are not described herein. Multiple attachingbosses 10 are disposed at the resin case 7, and the printed circuitboard 9 is fixed to the attaching bosses 10 through screws 11. Asillustrated in FIG. 1, the attaching bosses 10 extend to the bottom fromthe top.

A penetration connector 12 is integrated with the resin case 7. Thepenetration connector 12 extends upward as shown at the right side ofFIG. 1. The penetration connector 12 penetrates a partition wall of theT/M case 1, and protrudes to the outside of the T/M case 1. The tipportion of the penetration connector 12 is a vehicle-side connector 13.One end of a vehicle-side wiring 14 is connected to the printed circuitboard 9, and the other end of the vehicle-side wiring 14 is connected toa connector terminal of the vehicle-side connector 13. The vehicle-sideconnector 13 is used for electrically connecting the TCU 3 to a controlapparatus at the vehicle side. A seal member 15 is disposed between thepenetration connector 12 and the partition wall of the T/M case 1.

A load-side connector 16 is integrated with the resin case 7 asillustrated at the left side of FIG. 1. One end of the load-side wiring17 is connected to the printed circuit board 9, and the other end of theload-side wiring 17 is connected to a connector terminal of theload-side connector 16. The load-side connector 16 is used to connectthe TCU 3 to a device, which is objected to be electrically controlled,inside the valve body 2.

As illustrated in FIG. 3, the resin case 7 is fixed to the metal base 4through multiple screws 18. As illustrated in FIG. 1, an oil-tightstructure 19 is formed at an inner peripheral part of the fixationlocation to surround an outer peripheral part of the printed circuitboard 9. The oil-tight structure 19 includes a groove 20, an oil-tightseal member 21, and a protrusion 22. As illustrated in FIG. 4, thegroove 20 is disposed at the metal base 4 as viewed from a surface ofthe metal base 4. As illustrated in FIG. 2, the oil-tight seal member 21is disposed at the groove 20. As illustrated in FIG. 5, the protrusion22 is disposed at the resin case 7 as viewed from a surface of the resincase 7. The oil-tight seal member 21 is made of, for example,fluororubber. The groove 20 may also be referred to as a recess.

A support member 24 is disposed at the metal base 4. The support member24 faces upward and supports the heat radiation member 23. The heatradiation member 23 may also be referred to as heat radiation adhesive23. When the resin case 7 is attached to the metal base 4, the lowersurface of the printed circuit board 9 is in contact with the heatradiation adhesive 23, which mounts on the support member 24. Withregard to the heat radiation adhesive 23, hardening treatment isprocessed after the assembly of the TCU 3. The heat generated by theprinted circuit board 9 is conducted to the metal base 4 through theheat radiation adhesive 23 and the support member 24, and then the heatis radiated.

FIG. 2 illustrates a cross-sectional shape of the oil-tight structure 19in a deformation form. In a situation where the resin case 7 is attachedand fixed to the metal base 4 and the protrusion 22 enters the groove20, the shape of each portion is set such that the thickness of theoil-tight seal member 21 in a vertical direction as illustrated in FIG.2 is larger than the thickness of the oil-tight seal member 21 in ahorizontal direction as illustrated in FIG. 2. For example, thethickness of the oil-tight seal member 21 in the vertical direction (ora first direction) is set about 2.0 mm, and the thickness of theoil-tight seal member 21 in the horizontal direction (or a seconddirection) is set about 1.0 mm. Therefore, it is possible to largelyreduce vibration in the vertical direction transmitted to the printedcircuit board 9 in a situation where the vehicle is travelling. Hence,vibration-proof characteristics may be enhanced.

The following describes a flow of assembling the TCU 3. As illustratedin FIG. 6, the heat radiation adhesive 23 is coated on the metal base 4,which is applied with the anodizing treatment, at S1. Subsequently, theoil-tight seal member 21 is coated inside the groove 20 at S2. The resincase 7, which is assembled with the printed circuit board 9, is appliedwith plasma cleaning at S3. The resin case 7 is assembled with the metalbase 4 at S4 and then applied with heat treatment, the oil-tight sealmember 21 and the heat radiation adhesive 23 are hardened and then cooldown at S5.

By performing the process described above, the anodized metal base 4 andthe oil-tight seal member 21 are at a hydrogen bonding state. The resincase 7 processed by the plasma cleaning treatment and the oil-tight sealmember 21 are at a covalent bonding state. In other words, hydrogenbonding is formed between the metal base 4 and the oil-tight seal member21, and covalent bonding is formed between the resin case 7 and theoil-tight seal member 21.

As illustrated in FIG. 1, a ventilation hole 25 is formed in thepenetration connector 12. The ventilation hole 25 allows communicationbetween interior space and exterior space of the TCU 3. The printedcircuit board 9 is stored in the interior space of the TCU 3. Abreathable filter 26 having air permeability is disposed at a locationwhere the ventilation hole 25 faces the external space. A cover 27 isdisposed outside the breathable filter 26.

According to the present embodiment, the TCU 3 is disposed under anenvironment where the interior of the T/M case 1 may be covered by theATF 50. The TCU 3 includes the metal base 4 and the resin case 7. Theresin case 7 is integrated with the connector 12, and is attached to themetal base 4. The connector 12 penetrates the T/M case 1. The electroniccomponent 8, which is included in the control circuit for transmission,mounts on the printed circuit board 9. The printed circuit board 9 isdisposed in the interior space formed between the metal base 4 and theresin case 7. The oil-tight seal member 21 is disposed between the metalbase 4 and the resin case 7 to surround the periphery of the printedcircuit board 9. The penetration connector 12 has a ventilation hole 25communicating between the interior space of the T/M case 1 and theexterior part of the T/M case 1, and the breathable filter 26 isdisposed at a location where the ventilation hole 25 faces outside.

Since the space formed between the metal base 4 and the resin case 7 hascommunication with outside through the ventilation hole 25, the interiorpressure may not change as the temperature inside the T/M case 1changes. Hence, it is possible to reduce stress applied to thestructure. It may be possible to inhibit a situation in which foreignsubstances enter the T/M case 1 by disposing the breathable filter 26 ata location where the ventilation hole 25 faces outside.

Since the ventilation hole 25 is provided at the penetration connector12, it may be possible to reduce the size of the TCU 3. Since the cover27 is provided to cover at least a part of the breathable filter 26, itmay be possible to avoid a situation where the breathable filter 26 istouched and damaged when an operator performs installation or the like.

The metal base 4 and the oil-tight seal member 21 are at a hydrogenbonding state, and the resin case 7 and the oil-tight seal member 21 areat a covalent bonding state. Therefore, the adhesive strength may beenhanced to prevent the ATF 50 from entering the interface between themetal base 4 and the oil-tight seal member 21 and the interface betweenthe resin case 7 and the oil-tight seal member 21.

Since the metal base 4 is made of aluminum and applied with theanodizing treatment and the resin case 7 is applied with the plasmatreatment, the interface formed between the metal base 4 and theoil-tight seal member 21 is set to an optimal state for hydrogen bondingand the interface formed between the resin case 7 and the oil-tight sealmember 21 is set to an optimal state for covalent bonding. Since theoil-tight seal member 21 is made of fluororubber, a material havingrelatively high resistance to the ATF 50 and having flexibility may beused.

The groove 20 for accommodating the oil-tight seal member 21 is formedat the metal base 4. The protrusion 22 is formed at the resin case 7 topress the central portion of the oil-tight seal member 21. The shape ofthe groove 20 is set such that, when the resin case 7 is attached to themetal base 4, the spacing in an extension direction from the tip of theprotrusion 22 has a longer width than the spacing in a directionperpendicular to the extension direction. Therefore, it is possible toreduce vibration in a vertical direction (or the extension direction)transmitted to the printed circuit board 9 in a situation that thevehicle is travelling. Hence, resistance against vibration may beenhanced.

According to the present disclosure, the plasma treatment (or the plasmacleaning treatment) is performed on the resin case 7 to vaporize dirt ascarbon dioxide in order to eliminate the dirt on the resin case.Therefore, the dirt removal allows the resin case 7 to form strongercovalent bonding with the oil-tight seal member 21.

Second Embodiment

Hereinafter, the identical parts as those in the first embodiment aredesignated by the same reference numerals, and explanations thereof areomitted. Differences from the first embodiment are described. In the TCU31 according to the second embodiment as illustrated in FIG. 2, a femaleconnector 32, which is connected to the vehicle-side connector 13 as amale connector, includes a lever 33, which is rotatable to lock theconnection between the female connector 32 and the vehicle-sideconnector 13.

The lever 33 has: a one end that is rotatably supported by a housing 34of the female connector 32; and the other end that rotates in a rangeof, for example, 90 degrees between a depth direction and a downwarddirection as shown in FIG. 8. The depth direction is a direction goingaway from the plane of the drawing of FIG. 8. The connection of thefemale connector 32 is locked as illustrated in FIG. 8. In replacementof the cover 27, the lever 33 covers the outside of the breathablefilter 26. According to the second embodiment, the lever 33 of thefemale connector 32 is adopted as the cover of the breathable filter 26.Therefore, the number of components may be reduced.

Third Embodiment

In the TCU 35 according to a third embodiment as illustrated in FIG. 9,the female connector 36, which is connected to the vehicle-sideconnector 14, is similar to the one in the second embodiment forcovering the outside of the breathable filter 26. However, in the thirdembodiment, when the female connector 36 and the vehicle-side connector13 are connected, a housing 37 of the female connector 36 covers theoutside of the breathable filter 26.

According to the third embodiment, a part of the housing 37 of thefemale connector 36 is adopted as the cover of the breathable filter 26.Therefore, it is possible to reduce the number of components, as similarto the second embodiment.

Fourth Embodiment

In a TCU 38 according to a fourth embodiment as illustrated in FIG. 10,a female connector 39, which is connected to the vehicle-side connector13, is similar to the one in the third embodiment for covering theoutside of the breathable filter 26. Additionally, it is similar that ahousing 40 of the female connector 39 covers the outside of thebreathable filter 26. However, the female connector 39 includes anO-ring 41 for waterproofing. The breathable filter 26 is disposed tocover the space where the O-ring 41 and the connector terminal of thevehicle-side connector 13 as the male connector are located.

Fifth Embodiment

In a TCU 42 according to a fifth embodiment as illustrated in FIG. 11, afemale connector 39, which is connected to a vehicle-side connector 44,is similar the one in the fourth embodiment for covering the outside ofthe breathable filter 26. However, in replacement of the penetrationconnector 12, a penetration connector 43 allows communication betweenthe outside of the ventilation hole 25 and the inside of thevehicle-side connector 44. In this embodiment, the vehicle-sideconnector 44 replaces the vehicle-side connector 13. A communicationhole 45, which is communicable with outside, is formed at a part of ahousing of the vehicle-side connector 44. The breathable filter 26 isdisposed inside of the housing of the vehicle-side connector 44.

Sixth Embodiment

A TCU 46 according to a sixth embodiment as illustrated in FIG. 12 isdifferent from the TCU 3 according to the first embodiment. In thisembodiment, the breathable filter 26 is welded to the housing of thevehicle-side connector 13.

Seventh Embodiment

A TCU 47 according to a seventh embodiment as illustrated in FIG. 13 isdifferent from the TCU 3 according to the first embodiment. In thisembodiment, the TCU 47 has a plug-type breathable filter 48, whichreplaces the breathable filter 26 and the cover 27. The breathablefilter 48 has both functions of the breathable filter 26 and the cover27. The “Z-series” of a ventilation filter TEMISH (registered trademark)manufactured by Nitto Denko Corporation may be used as the breathablefilter 48.

Other Embodiments

The oil-tight seal member may not be limited to fluororubber. Theconfiguration of an oil-tight structure may not be limited to the oneillustrated in FIG. 2. An oil-tight structure may be formed by providinga protrusion at the metal bar and providing a groove at the resin cover.A cover for covering the breathable filter may be provided if necessary.The load-side connector 16 may be provided if necessary, and theconnection with the inside of the valve body 2 may be made directly. TheTCU 3 may not be disposed on the valve body 2.

Although the present disclosure has been described in accordance withthe examples, it is understood that the disclosure is not limited tosuch examples or structures. The present disclosure encompasses variousmodifications and variations within the scope of equivalents.Furthermore, various combination and formation, and other combinationand formation including one, more than one or less than one element maybe made in the present disclosure.

It is noted that a flowchart or the processing of the flowchart in thepresent application includes sections (also referred to as steps), eachof which is represented, for instance, as S1. Further, each section canbe divided into several sub-sections while several sections can becombined into a single section. Furthermore, each of thus configuredsections can be also referred to as a device, module, or means.

What is claimed is:
 1. A vehicle control apparatus disposed inside ahousing accommodating a transmission, the vehicle control apparatuscomprising: a metal base made of a metal; a resin case attached to themetal base to provide an interior space; a printed circuit board, onwhich an electronic component mounts, that is disposed in the interiorspace; and an oil-tight seal member that is placed between the metalbase and the resin case to surround the printed circuit board, whereinthe electronic component is included in a control circuit for thetransmission, wherein the metal base and the oil-tight seal member areat a hydrogen bonding state, and wherein the resin case and theoil-tight seal member are at a covalent bonding state.
 2. The vehiclecontrol apparatus according to claim 1, wherein the metal base is madeof aluminum and anodized.
 3. The vehicle control apparatus according toclaim 1, wherein the resin case is applied with plasma treatment.
 4. Thevehicle control apparatus according to claim 1, wherein the oil-tightseal member includes fluororubber.
 5. The vehicle control apparatusaccording to claim 1, further comprising: a recess that is disposed atone of the metal base and the resin case, and that accommodates theoil-tight seal member; and a protrusion that is disposed at the otherone of the metal base and the resin case, and that presses a centralportion of the oil-tight seal member accommodated in the recess, whereinthe protrusion has a tip extending in a first direction, and wherein, ina case of the resin case attaching to the metal base, a spacing from thetip to the recess in the first direction has a larger width than aspacing between the recess and the protrusion in a second directionperpendicular to the first direction.
 6. The vehicle control apparatusaccording to claim 1, wherein the resin case includes a part having aconnector disposed to penetrate inside and outside of the housing,wherein the connector includes a ventilation hole, which communicateswith the interior space between the metal base and the resin case andthe outside of the housing, and wherein the vehicle control apparatusfurther comprises a breathable filter disposed at a location where theventilation hole faces the outside of the housing.
 7. The vehiclecontrol apparatus according to claim 1, wherein the vehicle controlapparatus is placed at an atmosphere of lubricant oil, and is covered bythe lubricant oil.
 8. A method for manufacturing a vehicle controlapparatus, comprising: preparing a metal base made of a metal; preparinga resin case; preparing an oil-tight seal member; forming a groove atthe metal base; anodizing the metal base; coating the oil-tight sealmember inside the groove; performing plasma treatment on the resin case;and attaching the resin case to the metal base through the oil-tightseal member.